Filtering and packing material apparatus and method for making



July 8, 1941..

L. R SMITH 2.248,131

FILTERING AND PACKI NG MATERIAL APPARATUS AND METHOD FOR MAKING 4n Filed Nov. 1'7, 1937 I 2 Sheets-Sheet 1 2; l8 12 flea /6 /7 i 5 /20 x n ,44% WWLMM Aztarzzeys Pat ente d July 8, 194! agree:

FILTER-ING AND PACKING MATERIAL APPA RATUS AND METHOD FOR MAKING Leroy R. Smith, Pasadena, Calif. Application November 17, 1937, Serial No. 175,073

4 Claims. (01. 210-204) My invention in one of its phases relates to the method, the apparatus for making a filtering and packing material and to such material as a product. I have ascertained that in filtering liquids such as oils and especially in, filtering the crank-case oil of an internal combustion engine during the operation of such engine, that a "considerable improvement can be made in the filtering by the material used as the packing.

medium in the filter. Some of the packing materials now used include the so-called cotton waste and other fibers. In some cases it is desirable to treat the packing material with various chemicals toneutralize acids in the oil. In

some types of filters clay or similar'pellets are utilized which 'also have a neutralizing action on the acids'in the lubricating oils.

My invention as it relates to the filtering includes the manufacture of what I have termed a flock or flock pellets. These are preferably cut from waste ragsof either woven or knitted fabrics by cuts which are made at right angles one to the other, thus for instance presuming the rags are operated through the mill, a first, cut may be transverse to the leading edge. forming a series of transverse strings and then this bundle of strings is again cut by cuts transverse to the ends of the strings.

pending onthe type of fabric. For instance,

they may be made from all wool, cotton cloth or various grades of cotton and wool mixtures.

. For certain types of filters or other use, burlap,

linen, silks or equivalent materials may also form the base. As to the filter and similar use materials, my invention also comprehends makingthese of other waste products such as from paper,

cardboard or similar products of wood or paper In another way of manufacturing, the rags may be first slitted longipulp and many types of other fabrics or materials-which may be chopped in this form 1 where such scrap is in sheets and thus given the various cuts to develop the small pellets.

A; characteristic of these flock pellets is that the fibers have distinct and definite cutends L. find that for certain purposes suitable pele't's ,may be 'made from scrap leather, particularly an improved article over shredded or torn fibrous material such as cotton waste or similar. products. Moreover in the spinning of thread, in weaving and knitting of fabrics, the thread or yarn is twisted and the fibers and threads develop substantially permanent kinks. This per= manent kinkiness appears tobe due in great part to the material being. spunand woven or knitted in fabrics and having this permanent set usually for a long period during which the fabric from which the rags have been obtained has been washed or cleaned many times. Due to repeated washing and cleaning, the fibers are more absorbent.

Therefore the flock pellets formed from woven or knitted materials especially, have the characteristics of individual small cut pellets in which there are distinct end cuts: and the ilbershaving .the twist and the kinksdevelops a certain springiness resisting the tight packing of a mass.

of such pellets. Therefore I attain not only a better and an improved filtering material but also a product which has many advantages for packing various products.

Another feature of my invention relates to the treatment of the flock pellets to provide these with a chemical characteristic, in which case clean rags either damp or dry are impregnated with the chemical solution; The surplus of the chemical solution is removed, which may be done by drying rolls or by using a centrifugal drier; however the rags it slightly damp when subjected to the cross cutting action are more readily cut with true and clean distinct cuts as distinguished from a tearing operation. In another procedure to develop a flock for oil filters, the washed rags after being rinsed may be partially dried as in a centrifugal machine, oil may then be added, the oil displacing the water so that the oiled rags are subjected tothe cutting. In this case an improved cutting action is developed due to the rags being damp with the oil and the oil functions as a lubricant with the cutting knives in both of the cross cuts. Other materials, such as the flock cut from other types of sheet fiber material, may be likewise treated with chemicalsolutions or oils or both if desired to produce'a product suitable for particular purposes.

Another object and feature of my invention is to develop a fiockwith which'clay granules may be mixed, thls being especially adapted for oil filtration in which the clay has a neutralizing and refining action on the oil or gives other treatment. There are many oil filters in which various clay products ,are used in the filtration articles, etc.

and. in some instances the clay has been made order to prevent these breaking down and pack- -ing, somewhat hard clays are used. I I find that with my invention and employing the flock, a

soft clay of a .Bentonite type may be utilized.-

When this is in a granulated form it would be difiicult to prevent the breaking down of the granules. However when mixed with the flock which is one of the products of my invention, the packing of the flock around the individual granules of clay acts as a cushion in reducing the tendency of such granules to crush and disintegrate. The flock spaces the clay granules out of direct contact one with. another. Therefore the combination of a mixture of the fiockand the clay granules forms an improved mixture for use as a filter-refiner.

As a subsidiary development in making the clay granules for use with the flock, I find it advantageous to use certain binders'with the clay. This may be in the form of a liquid binder such as silicate of soda mixed with the clay and after drying the granules any dust may be removed by screening. Another manner of making the clay granules is' by mixing a fibrous type of binder such as asbestos.

Another use of the flock made in the form of pellets is that it forms an excellent air filter in air conditioning or the like. Such flock may be treated with an antiseptic or chemical and not only remove the dust but also acid gases and otherobnoxious gases-from the air. Another development is in mixing activated carbon in the form of granules with the flock in which case the fiock prevents crushing of the granules. The advantage of mixing a porous, absorbent material with the refining or purifying granules is that a freer passage of the gas or liquid through the filter-refiner is allowed; also in holding the rethe filter made from the procedure of Fig. 5 and illustrating the manner of inserting the oil feed tube into the packed filter.

Fig. 7 is a side elevation broken away of a filter unit adapted for oil filtration illustrating a unit made by the procedure of Figs. 5 and 6.

. Fig. 8 is an elevation similar to Fig. 5 showing another manner of packing. I

Referring first to the construction of'Figs. 1 and 2, a-washing, rinsing or solution applying machine is indicated by the numeral ll, this being shown as having a rotating drum of the type used for laundering and rinsing fabrics or other similar material. It will be understood howeverv that the rags or other material in sheet form may if desired be washed or cleaned by prior equipment not illustrated and the drum or similar machine designated by H may be used for adding a chemical solution as hereinafter detailed.

Following the treatment in the washer, rinser or solution machine II, the sheets are passed througha pair of drying rolls l2. These are of a known type and may be heated in any suitable manner and driven .to feed the material between the upper and lower rolls or there may be a set of rolls of varying temperatures. From the dryfining particles separate from each other, the

incoming gas or liquid can contact the entire surface of each refining particle. This may be used in air and gas purification. Manifestly the flock may be used in many other types of air filters such as those for internal combustion ennes.

The flock made from various materials also forms an excellent heat insulator for use at moderate or low temperatures. Certain grades of flock may be used for upholstery, packing fragile My invention is illustrated in connection with the accompanying drawings, in which:

Fig. 1 is a plan in diagram of a plant or equipment for cross cutting the layers of sheet material or fabric followed by. end .cuts on the strings or ribbons. Fig. 2 is a vertical section on the line 2-2 of Fig. 1 illustrating a type of eccentric cutting e to cut the threads, strings or ribbons into short lengths.

Fig. 3 is a side elevation in diagram of a. plant for first slitting the layers of sheet material or fabric to form longitudinal strings or ribbons followed by a cross or transverse cut to develop the oc c.

Fig. 4 is a front elevation on the line 6-6 of Fig. 3 showing a double acting shearing knife.

Fig. 5 is an elevation of equipment for packing a filter, such being partly broken away and showmg lower and upper sections of the filter with the filter material confined by a removable sleeve.

Fig. 6 is a side elevation partly broken away of ing rollassembly the dried or partly dried material is shifted to the sorting table l3. On this table the operatives may spread the fabrics 0 other sheet material sorting the rags where suc are used to feed those of a similar type to the cutting part of the machine. It is however preferable to pass similar types of material through the machine II and the drying rolls at the same time in which case the sorting table is used to flatten the articles spreading these for the further operation.

' The spread sheet material such as fabric is then transferredto a-conveyor l4 this being illustrated as *an endless belt type, the sheets being placed on the upper run, this upper run movin in the direction of the arrow Hi. This conveyor may .be of quite considerable length affordin opportunity for the operatives to continue the spreading of the rags. or other materlal to obtain the desired out. It will bigunderstood that for instance dealing with-rags, it is not necessary that the cuts be made parallel to the woof or the warp of woven fabrics as the cuts may be made on the bias. This also applies to knitted materials. Therefore it is not necessary to take particular care as to the exact arrangement of the materials to be cut on the conveyor and in leading these to the cutter.

The sheet material when properly arranged on the conveyor is next engaged by a pair of feed rolls indicated at l8, such being an upper and a lower pair of any conventional assembly for feeding sheet material. Such material is conveyed over a stationary knife I! mounted on a substantial table.

. The sheet material is then cut by a chopper l8. This has a drum-like structure IS with a series of knives 2i), the knives being arranged at an inclination in reference to a longitudinal line on the drum in order to give a shearing cut. Such drum or chopper may be rotated in any suitable manner and at the desiredspeed so that the knives 2B coact with the stationary knife I1 and make a series of complete transverse cuts through the layers of sheetmaterial being fed to the cutter. This develops a multitude of strings, threads or ribbons by distinct cross cuts or cross chopping.

The material so cut into the strings, ribbons :r the like falls by gravity from the stationary :nife I! and in part forced downwardly by the 'otating blades 20 onto a cross feed conveyor 25. ['his is illustrated as of the endless belt type iaving an upper run 26 operating in the direction )f the arrow 21. This conveyor may be quite iarrow as the strings or ribbons drop downwardy in bunches according to the number of layers :hopped by each of the knives 20 in the sequence )f its rotational operation.

At the discharge end of the conveyor 25 I emiloy a second stationary knife assembly 30. This:

-;he trough and of the side bars are preferably in vertical alignment. The trough causes the ounches of strings or ribbons to be more or less located at the bottom of the V from which they are not readily displaced.

The next operation is by a cross cut knife designated by the assembly 40. This as-shown in detail in Fig. 2 has a rotating disc 4| with a complete peripheral cutting edge 42. The center of rotation such as by the drive shaft 43 is eccentric to the disc. This cutting discis shown as being operated at a' relatively high peripheral speed through the medium of. a pulley 44 and a drive belt 45. Due to the eccentric mounting of the cutting disc or wheel on its shaft, a type of combination shearing and slicing cut is developed. The direction of rotation is indicated by the arrow 46. The peripheral cutting edge thus crowds the bunches of strings or ribbons into the inverted apex of the V shaped trough and gives a shearing action in conjunction with the end edges of the blades 3i and 32; If any material is crowded over to the bars 35 and 3 3 it is cut as the periphery of the blade reaches the remote bar. Due to the rapid rotation of the cutting disc in reference to the speed of the conveyor 25, there can'be very little of the bunches of threads pile up against the advance side of the disc cutter.

The double cut material then in the form of fiock is deposited on an endless conveyor 50, there being a suitable transfer apron located below the travel of the knife 42 and below the trough. This conveyor is illustrated as of the endless belt, type and moves the fiock laterally in reference to the first mentioned part of the machine .or if desired this conveyor may take the double chopped flock in any desired direction.

For certain purposes of use of the flock if it is too damp, even after passing through the drying rolls I2, I submit the fiock to a dryer 55. This is illustrated as a rotary dryerin which the axis extends longitudinally in reference to the travel of thematerial and at a downward inclination. Therefore the flock is fed forwardly and at the same time tumbled in this rotary dryer. I find that in cutting sheet material such as flock made from less or the like, that a much cleaner chopping job may be done by having the layers of material damp instead of as dry as possible. The knives both of the chopper i8 and of the end cutting disc give much cleaner cuts on slightly damp material than on thoroughly dried fabrics or the like and produce much less lint or material too fine for the various purposes to which my type of flock may be applied.

Dealing next with the plant of Figs. 3 and 4, which as to certain features is designed to extract moisture from the fabrics or sheet material and to then impregnate the material with an oil or other liquid to displace the rinsing water or the like. In this construction the sheet material is first slitted longitudinally and then the strings or ribbons given the transverse end cuts. In this construction a washer .or rinser is indicated by the assembly numeral 15. This may be a rotary laundering drum or equivalent machine. The rags and the sheet material are then transferred to a centrifugal dryer I6 which may be of an ordinary type operated to reduce the water or moisture content to a greater degree than;for instance the drying rolls l2 of Fig. 1. A liquid supply pipe 11 is positioned to be introduced into the centrifugal dryer and this has spray jets 18 positioned to discharge a spray of liquid on the material after subjecting to drying or partial drying. This spray assembly may be utilized to discharge on into the centrifugal dryer. The oil first sprays on the material while it clings to the walls of the centrifugal dryer basket by a centrifugal force. This develops an outward flow of oil causing a displacement of the rinse water until all of the material in the centrifugal dryer is dampened to a desired degree with the oil. The sheet material is then removed from the dryerand transferred to a sorting table 80 which may be utilized as the sorting table [3 of Fig. l. The sheet material may be spread out flat and built up in a number of layers. veyor 8| having its upper run moving in the direction of the arrow 82 then carries the material to a slitting machine 85. This has an initial pair of feed rollers 86 positioned one above the other and having a transfer apron 81. These rollers smooth the layers of sheet material which are then passed through slitting discs 88, this being shown as having a lower assembly 89 and an upper and larger set of knives 90. These may be of a known and standard type for slitting material into very narrow strips such as long strings or ribbons. After slitting these are next picked up by a pair of outfeeding rollers or drums 9|, one being positioned above the -other. If desired transfer aprons or the like are utilized.

The longitudinally slit material is then delivered to a transverse cutting machine Hill. This has lower and upper guide plates HH' and 102, note Fig. 4, with a space I03 therebetween for the passage of the strings or ribbons. Each of these guide plates is provided with a cutting end or blade [04 and coacting with these is a double acting shearing blade -l05 pivoted at it to a fixed structure. This blade has upper and lower cutting edges I01 and H18 and is oscillated by means of an operating link I09 or the equivalent.

The flock thus formed by the slitting machine and the transverse cut for the cords or ribbon drops to an outfeeding conveyer H5. gThis is illustrated as of the endless belt type, the upper run operating in the'direction ofthe arrow H6. If the flock is not sufiiciently dry it is then transferred to a'mechanical dryer I20. This is preferably a heating dryer of the type having a rotating drum. It will thus be seen that by the equipment of Figs. 3 and 4 the raw sheet material may be treated to wash and rinse, remove a desired proportion of the water or other cleansing solution by the centrifuge. Oil or other liquid may be added to the fabrics. These after proper spreading and building up in layers are then sub- An endless belt con-' jected to the slitting machine. Incidentally this slitting for woven or knitted fabrics or the like may be parallel to the threads or on the bias. By proper construction of the slitting machine the desired width of cords or ribbons may be obtained and then these out or chopped by the oscillating knife to the desired length.

It is manifest that the flock may be cut from graded and sorted materials and cut or chfopped to form pellets of different sizes depending on the purpose for which the flock material-is to be used. I find it is difficult to screen the fiock pellets to various sizes and the control of the size is better obtained by regulating the cutting and chopping. However for coarse material I cut and chop the flock to pass through for instance A inch mesh and this may be graduated in size by fine cutting to form a lint which would pass for instance, 50 mesh.

Moreover where it. is desired to have flock pellets which will provide a coarse screen, it is preferable to out these from all wool fabrics of a good quality. A finer filtering and screening material may be made from cloth rags of a cotton wool mixture. The finer materials for use in filters or the like is preferably made from all cotton or linen fabrics.

In some cases for various types of operations I mix with the flock granules of different materials such as clay granules or those of activated carbon. Granules may be made of calcium hydroxide or silicate of soda for neutralizing oil. Clay granules are used for neutralizing and removing unsaturates from the oil. These granules may be made in any suitable manner and may be graded in sizes say from those passing a inch mesh to a so-called 40 mesh. The flock may be treated with a number of chemicals depending on the use to which the material is put and as above mentioned it is preferable to treat the raw material from which the flock is cut or chopped prior to this cutting and chopping operation. For the purpose of neutralizing the acidity of oil I may treat the flock for instance with a solution of silicate of soda, sodipm carbonate or triethanolamine. This material may also be used for removing acid gases from air and this type of flock forms an excellent material for use in air conditioning plants as an air filter. It may be saturated with antiseptics or odor removing chemicals such as hexyl resorcinol.

An important characteristic of the flock when used with clay granules, granules of activated carbon and other readily crushable material in small particles is that when properly mixed with more or less coarse flock the fiock holds the granules in position and not only prevents their packing but breaking down into fines which for most purposes is disadvantageous. Therefore I secure an improved mixture by using the flock in the form of pellets made from cut and chopped material with the granules of other materials.

In order to show an application of my invention in the use of the flock and granules, in Figs. 5 through 8 I illustrate the procedures for pack- Ing filters and a filter adapted for filtering cyl..

inder oil of an internal combustion en ine. Referring first to the completed filter of Fig. 7, this has a metal shell provided with a bottom cup I 26 and an upper cup I27. Each of these has a cylindrical side wall I28 and connected by an having an opening I32. A drain-cock I33 is attached to the sump for cleaning dirt or other material accumulating in the cone and the sump. A perforated disc and/or screen I3! is placed in the bottom cup engaging the cone at its base, that is, at the junction line with the cylindrical side wall. The upper cup has a slightly domed head I35 and is provided with a central opening I36 and also with one or more additional openings I31. At each of these latter openings an outlet connecting ferrule I38 is attached. A perforated metal disc and/or screen I33 is fitted in the upper cup below the dome and adjacent thereto I have one or more pads of felt or cotton indicated at I40. The packing indicated by the assembly numeral I45 has alower coarse layer I46 preferably made of flock pellets from pure wool fabric and cut or chopped rather coarse. Above this there is a second layer I-I'I preferably made of pellets from a cotton and wool mixture, these being of smaller size. The chemically treated layer I48 has incorporated therewith clay granules or granules of other suitable material mixed with the fiock pellets These flock pellets may be chemically treated if desired. The upper layer M9 is preferably made of flock cut from cotton rags or the like and has the finest out. An oil supply tube I50 extends downwardly through both of the cups and'has a'screw threaded nipple I5I for attachment of an oil feed pipe. The pipe is sealed by known practiceto the head; I35 at the opening I36. It extends downwardly through the upper perforated disc I33, thelayers of fabric and also throughthe lower perforated The preferred manner of filling such a filter is' shown inFig. 5 in which the lower cup is -suitably supported and around this is fitted a packing sleeve I60. This is cylindrical and has a close fit outside of the cups. The packing isthen placed in the lower cup and in this sleeve in layers which layers need not be separated by any definite line. The upper cup I2! is then forced downwardly on the mass of more or less loose packing and compresses this until the two cups engage at the joint I29. The sleeve may then be removed and this joint finished to make an oil tight connection of the upper and lower cups. When so connected however the layers of packing extend across the whole diameter of the cups and 'it is necessary to insert the tube I50. This is done by the procedure shown in connectionwith Fi 6 in which a pointed needle I65 has a projecting stud I66 and from the top and over this is fitted the tube .I 50. The assembly of the needle and the tube is then inserted through the opening I36 in the dome I35. the point of the needle forcing an opening through the perforatedmetallic disc I39. It also pierces and spreads the felt or fabric layers MI) and is forced through the various layers of the, packing causing a lateral spreading, perforating the lower perforated disc I34 and the needle being pulled out through the sump I 3|, and the bottom opening I 32. This leaves the tube I50 extending through the complete packin which is retained in place by the upper and lower perforated discs. The forcing of the needle through these discs forms a slight downturned burr which is .operative to frictionally enga e the tube. However as above mentioned, the tube is held in place by the attachment of the threaded nipple end l5l to the dome I35 either by soldering, welding or by a screw threaded connection.

-The manner in which the needle I65 is thrust through perforated discs or screens such as I39 and H4 is apparent to those skilled in the art,-

the needle being mainly used as a guide for the tube H and to form an opening through the packing or similar material for such tube. The tube thus extends above the upper perforated disc or screen 839 and preferably slightly below the lower disc or screen 13%. Manifestly the per-.

forations through the screens or discs made by the needle should be such that the oil does not tend to fiow along the periphery of the tube I50 through the filter material.

In Fig. 8 I show an alternative manner of filling the filters. In. this case the various layers of the packing are placed in a sack or sacks indicated at llii. The sacks are of such a diameter that they may be conveniently fitted in the lower cup-of the filter and confined by the sleeve Hill. Then when the upper cup is forced downwardly it compresses the packing and stretches the cloth sacks forming a close contact with the inner walls -of the filter shell. When the joint 829 is sealed,

the tube i 50 may be inserted in the manner illustrated and described in connection with Fig. 6, thus completing the filter.

It will be understood that I vary the pack in the filters depending on the particular purpose to be accomplished but it is preferable to have the flock graded as shown in the construction of Figs. 5 and '7 and'also in the construction of Fig. 8the fiock may be graded in the sack or cloth casing or a series of small sacks may be made one with each type of layer and the pack made by inserting a plurality of small sacks. The flock, whether or no it incorporates granules of other materials, should not be so tight as to require excessive oil pressure but likewise the pack must not be sufilciently loose so that the oil will develop a free passage therethrough. If find however by usin'g' fiock made in accordance with my invention there is less tendency for a'inore or less loose filter to open and allow channels for the passing of oil than in filters made with materials now used. One of the v.diiliculties in filtering crank case oil of internal cgmbustion engines is that practically all of these-oils develop an emulsion which tends to clog "the filter. With my filter pack properly made it will retain these emulsions. In some cases I find it of an advantage to incorporate in the flock a permanent emulsion of oil and water. and this may be done by adding a certain amount of a soap or soap ingredients such as triethanolamine and oleic acid in which the soap may vary from about 3 to not more than 10% of the emulsion of oil and water with water soluble chemicals.

It is to be understood also that the flock may be utilized to incorporate granules of hard materials as well as those readily pulverized and in addition to reducing the crushing or disintegration of the granules, the fiock retains these spaced apart so that the liquids or gases passing through the filter may come in contact with the complete surface of the granules. While I have described the flock as made mainly from fabrics, it is to be understood that I may also make this from raw fibrous material such as cotton, wool, linen, hair or other suitable fibers and in these instances it is also desirable to make the cuts at substantially right angles one to the other. This may therefore produce either extremely short fibers or those of considerable length. It is manifest that the flock made from fabrics may be cut so fine that the individual fibers are practically separate one from the other. One of the features that develops excellent absorbing qualities is due to the sharp cuts .on the ends of the fibers exposing such ends for an absorbing action.

Various changes may be made in the details of the construction without' d parting from the spirit or scope of the invention as defined by the appended claims.

I claim:

1. In the method of making fiocculent pellets of the type described, characterized by short tubular chemically reactive intersecting fibers comprising utilizing sheet material having a multitude of relatively long tubular fibers similar to woven, knitted or felted materials, moistening the sheets with a chemical having the characteristics of being reactive when filtering, subjecting the sheet materials to a succession of cuts to first produce string-like strands and then cutthe strands into short lengths to produce the pellets of the desired size, all of the cuts leaving cleannon-crushed ends of the tubes of the fibers whereby such ends may function in the absorption or liquids, mixing the chemically saturated pellets with granular material of a type readily pulverized to thereby embed the granules in the fiocculent pellets with the pellets forming a cushion for the granules and then shaping the mass of pellets and the granules to form a filter.

2. In the method of making a filter from a base absorbent material of kinky twisted organic tubular fibers comprising moistening' the base material with a chemical which is reactive when filtering, cutting the base material and re-cutting the cuttings to produce fiocculent pellets with individual fibers having clean cut noncrushed ends of the tubular fibers, the cutting and re-cutting farming as to individual fibers a capillary tube open at both ends whereby such ends function in absorption of liquid, mixing the chemically saturated pellets with a chemically reactive and adsorbent granular material of a type readily pulverized to thereby embed the granules in the fiocculent pellets with the pellets forming a cushion for thepulveriz'able granules and then shaping the mass of pellets and the granules to form a filter.

3. In the method of making an oil filter comprising utilizing a base organic absorbent material having kinky twisted tubular fibers, moistening the base material with oil' to drive out water, cutting the base material and re-cutting the cuttings to produce fiocculent pellets with individual fibers having clean-cut non-crushed ends of the tubes of the fiber to develop as to individual fibers a capillary tube open at both ends whereby such tubes function in a capillary manner in the absorption of the oil and then shaping the mass of pellets to form a filter.

4. In the method of making a filter comprising using a base organic absorbent material having kinky twisted tubular fibers, cutting the base material and re-cutting cuttings to form fiocculent pellets composed of kinky twisted tubular fibers with, non-crushed open ends of the tubes, producing the sharp cut fibers in sufllciently short lets to form a filter.

LEROY B. SMITH. 

